Packaging material register control



` March 8, 1966- R. E. .MILLER ETAL PACKAGING MATERIAL REGISTER CONTROL 4 Sheets-Sheet l Filed March 6, 1963 ffzyflzrars March 8, 1966 R. MILLER ETAL.

PACKAGING MATERIAL REGISTER CONTROL Filed March 6, 1963 4 Sheets-Sheet 2 March 8, 1966 R. E. MILLER ETAL 3,238,691

PACKAGING MATERIAL REGISTER CONTROL Filed March 6, 1965 4 Sheets-Sheet 5 March 8, 1966 R. E. MILLER ETAL PACKAGING MATERIAL REGISTER CONTROL 4 Sheets--Sheeerl 4 Filed March 6, 1963 www @E United States Patent O f PACKAGING MATERIAL REGISTER CONTROL Roland E. Miller, Orangeville, George Howard Kraft,

Wilmette, Carmen G. Tumino, Elk Grove Village, and

Clyde D. Wayne, Wilmette, Ill., assignors to National Dairy Products Corporation, Chicago, lll., a corporation of Delaware Filed Mar. 6, 1963, Ser. No. 263,316 8 Claims. (Cl. 53-3) This invention relates to a method of packaging food products in individual serving containers, and to apparatus for practicing such method.

In the marketing of certain products, particularly .food products such as jellies, jams, cheeses and the like, it is frequently desirable to Vsupply individual servings of the product in small packages. One such package and a method by which it may be formed is shown in U.S. Patent No. 2,736,656, which patent is assigned to the assignee of the present invention. By the method disclosed in that patent, an elongated strip of Ithermoplastic material is formed into a series of longitudinally spaced cups while leaving a horizontally extending border flange around each cup. The cups are successively filled with the material to be packaged, and a continuous cover sheet of thermoplastic material is then secured to the border flanges of the cups, the cover sheet being disposed so as to extend across the mouths of the cups, thereby sealing the product within the cups. The cups are subsequently severed from one another to provide the finished packages.

It is customary for the distributor of such packages to provide the covering sheet with a printed message containing, for example, his trademark, the ingredients of the package, and instructions as -to the most convenient method of opening the package. The message is normally printed on the cover sheet before the cover sheet is secured to the cups. Hence, in order to insure that lthe complete message will appear at least once on each package, it is generally brief and is preferably repeated several times within an area the size of the upper surface of one package.

While the above referred-to method of marking packages has proven satisfactory, it is, of course, more desirable to provide the cover sheet with a single complete or integral message, as by providing the cover sheet with a series of integral messages and causing one of the messages to register with each of the cups. Such a package is, among other things, more attractive, and the single integral message conveys the stated information more effectively. However, prior to the present invention, no practical method or apparatus Was available by which the package could be formed while assuring a registry of one of the messages with each of the cups.

Accordingly, the principal object of the present invention is to provide an improved method and apparatus for packaging individual food servings.

Another object of the invention is to provide lan improved method and apparatus for producing such a package, by which method and apparatus a cover sheet having a series of integral surface markings thereon is secured to an interconnected series of cups in such a manner that one of the surface markings is in registry with each of the cu s.

further object of the invention is to provide an apparatus for disposing a cover sheet provided with a series of integral surface markings in overlying relation to a series of longitudinally spaced cups so that one of the markings is in registry with each of the cups within predetermined limits, which apparatus includes means for detecting a deviation of the registry from within the predetermined limits, and means for compensating for the deviation.

ICC

Other objects and advantages of the invention will become apparent with reference to the following description and accompanying drawings.

In the drawings:

FIGURE 1 is a schematic perspective illustration of a method incorporating various of the features of the invention;

FIGURE 2 is an enlarged, partially broken-away, fragmentary perspective View illustrating one step on the method shown schematically in FIG. 1;

FIGURE 3 is a fragmentary elevational view of a row of interconnected cups as they might appear prior to being filled and covered to form the completed packages;

FIGURE 4 is an enlarged fragmentary partially brokenaway end view of a cup-forming apparatus incorporating various of the features of the invention;

FIGURE 5 is a fragmentary elevational view, partially in section, of the apparatus shown in FIG. 4;

FIGURE 6 is an enlarged fragmentary sectional elevational view taken along line 6-6 of FIG. 4;

FIGURE 7 is an enlarged fragmentary partially brokenaway end View of a portion of the apparatus shown in FIG. 6;

FIGURE 8 is a fragmentary side elevational view of an apparatus for securing a cover sheet to cups such as those shown in FIG. 3;

FIGURE 9 is an enlarged fragmentary sectional elevational view of the apparatus shown in FIG. 8;

FIGURE l0 is an enlarged fragmentary partially broken-away elevational view of a portion of the apparatus indicated in FIG. 8, as viewed in the direction of the arrows 10--10;

FIGURE 11 is a fragment-ary sectional elevational view taken along line 11-11 of FIG. 10;

FIGURE 12 is an enlarged sectional elevational view of an apparatus Ifor removing a portion of the border flange from each of the cups of FIG. 3;

FIGURE 13 is an enlarged sectional elevational view of an apparatus for trimming the border flanges of the cups and severing them from one another; and

FIGURE 14 is a fragmentary plan View, partially in section, of the die shown in FIG. 13.

The apparatus of the present invention can best be understood by reference to the method which is practiced when the apparatus is operated, which method is shown schematically in FIG. 1. By this method, a strip 21 of thermoplastic material is formed into a pair of longitudinally extending parallel rows of open-topped containers or cups 23, the mouth of each of which is encircled by a border ange 2S. The cups of each row are longitudinally spaced from one another and are interconnected with the adjacent cups of the row, such adjacent cups being hereinafter referred to as preceding or succeeding cups or containers depending upon their relative positions in the row, by that portion 27 of the border ange which extends longitudinally of the row. Each cup is interconnected with an adjacent cup of the co-parallel row by that portion 29 of the border flange which extends transversely of the rows. In the forming of the cups, the border flange is offset downwardly, leaving a raised rim 30 surrounding the mouth of each cup. The lips of adjacent cups of each row define therebetween a groove 31 extending generally transversely of the row.

A cover sheet 33 provided with a continuous ser-ies of integral surface markings 35 is brought into overlying rel-ation to the formed cups so that each of the markings is approximately, but not necessarily precisely, in registry with the upper surface of one of the cups, i.e., disposed, within limits, in a predetermined position relative to the upper surface of one of the cups. When the registry of the surface markings relative to the cups begins to fall outside predetermined limits, as when the surface markings begin to lag behind the cups by more than a predetermined amount, the cover sheet is moved forward slightly relative to the cups and a portion thereof is tucked into the grooves 31 of the flange to form a pocket, so to speak, of excess covering material, thus taking up the lag and restoring the registration to within the predetermined limits.

The overall operation of the improved apparatus for practicing the method can best be understood with reference to FIG. 1 of the drawings. Very generally, in the operation of the apparatus, the continuous relatively narrow strip 21 of thermoplastic material is fed into a forming station 39 where the strip is heated and then formed into the parallel rows of longitudinally spaced series of cups 23 as -by blow molding or the like. The formed cups are moved to a blanking station 41 Where a portion of the transversely extending flange 29 is removed, and are subsequently moved to a feeding station 43 where the product is dispensed into the cups. The filled cups are moved into a covering station 45 where the cover sheet 33 is secured to the upper surface of the border ange and where the tucking, if any, takes place to insure registry of one of the surface markings 35 with each package. Finally, the lled and sealed cups are moved to a trimming and severing station 47 where they are separated from one another to provide the finished packages.

The movement of the material through the apparatus is intermittent, i.e., the material is moved forward, i.e., toward the right in FIG. 1, an increment at a time and is stationary for a suliicient length of time between movements for each of the stations to perform its respective operation. The movement of the material may be accomplished by any of a number of means well-known in the art, such as, for example, as shown in U.S. Patent No. 2,736,150, which patent is assigned to the assignee of the present invention. Accordingly, the details of construction of such means will not be described herein.

F arming station The mechanism of the cup forming station 39, FIGS. 4 through 7, comprises generally a heating unit 49 which heats the strip 21 to a temperature at which it can be easily formed, and a blow-molding unit 51 by which the strip is molded into the series of cups. The two units are aligned with one another along the path of strip movement and are positioned, in the order named, in the direction of strip movement. Each heating and molding unit comprises an upper and a lower component, each of which components is vertically reciprocated into and out of cooperating engagement with the other.

More specifically, the upper components of each of the heating -unit 49 and the blow-molding unit 51 are suspended from an inverted T-shaped beam 53 in overhanging relation to the path of movement of the strip material. The beam 53 extends transversely of the path of movement and includes a vertically disposed slide plate 55 at each end which is movable in a vertical guideway 57 provided in a side wall 59 of the frame structure of the apparatus. A boss 61 projects from the inner surface of each ofthe slide plates 55 and has attached thereto a pitman 63 which connects the slide plate with a follower 65. The follower 65, in turn, rides within an eccentric groove 67 of a cam wheel 69 which is mounted on a shaft 71 4rotatably journaled in the frame and which is driven through remote connection to a power means (not shown). Rotation of the shaft, therefore, causes vertical reciprocatory movement of the upper beam 53 and, hence, of the upper components of each of the heating and blowmolding units, hereinafter described.

The lower component of each of the heating and blow molding units 49 and 51 is carried by a box beam 73 which is supported directly beneath the upper beam 53 and beneath the path of strip movement. The lower or box beam 73 is provided with an opening 75 adjacent each of its ends through which pass the driving pitmans 63 of ythe upper beam. A vertically disposed slide plate 77 is secured to each of the opposite ends of the beam 73 and is positioned for slidable movement within the vertical guideway 57, previously referred to, in which the slide plat-e 55 of the upper beam 53 moves. A bracket 81 depends from the lower `surface of the beam 73 adjacent each of its ends and has mounted thereon a follower y83 which rides in an eccentric groove 85 of a second cam wheel 87 which is also mounted on the shaft 71 which carries the first cam wheel 69.

It will be seen, therefore, that rotation of the shaft 71 causes vertical reciprocatory movement of the upper and lower beams 53 and 73. This movement is such as will cause the heating and blow-molding units 49 and 51 mounted thereon to be carried toward and away from one another into and out of substantially simultaneous Contact with the strip 21 which passes between them.

The upper and lower components of the heating unit 49 are disposed in vertical alignment with one another. The upper unit comprises a post 89 which is rigidly mounted on the upper reciprocal beam 53 and includes a transverse passageway adjacent its lower end. The upper and side walls of the passageway 95 are defined by the post 89, while the lower wall thereof is defined by the upper surface of a platen 96 secured to the lower end of the post 89 and provided with `a fiat lower surface engageable with the strip. A conduit 97 (FIG. 4) connects the passageway 95 to a source of heated medium (not shown), which medium is circulated through the passageway so as to heat the platen 96.

The lower component of the heating unit 49 comprises generally a hollow rectangular horizontally disposed tube 98 having a large passageway 99 therethrough which is connected by a conduit 101 to the source of heated medium. To insure that there will not be an excessive 4amount of pressure on the strip when the platen 96 of the strip is engaged by both the upper post 89 and by the lower tube 98, the tube 98 is slidably carried on four studs 103 which project upwardly from the lower beam 73 and is biased to a position adjacent the upper ends of the studs. When the pressure on the lower tube exceeds the biasing force, the tube slides downwardly on the studs, thus relieving the pressure on the strip.

More specifically, the tube 98 is carried on the upper surface of a block 105 provided with four spaced-apart vertically disposed holes 107, each of which is adapted to receive one of the studs 103 and each of which is countersunk, as at 109, adjacent its upper end to receive a head 111 of the stud. The countersunk portion of the hole is deep enough to permit limited vertical movement of the head of the stud therein, movement of the head in one direction being limited by the lower wall of the tube 98 which overlies the holes, and movement in the opposite direction being limited by engagement of the head of the stud with the base of `the countersink. A coil spring 113 encircles each stud and biases the block 105 and, hence, the tube 98 into its uppermost position on the studs.

The block 105, is therefore, normally carried in the uppermost position on the studs, as seen in FIG. 6. When the upper and lower beams 53 and 73 reciprocate toward one another, the platen 96 of the post 89 and the tube 98 engage opposite sides of the strip substantially simultaneously, but before the lower beam 73 has reached its uppermost point of travel. Continued upward movement of the lower beam 73 urges the tube 98 downwardly and compresses the coil springs 113. The pressure exerted on the strip by the heating unit 49 is thus determined by the force of the springs 113 and can be easily controlled by selection of the proper springs.

The molding of the cups is accomplished by simultaneous engagement of the pre-heated portion of the strip by the blow-molding unit 51 which comprises a blow pipe 115 suspended above the strip and a mold 117 supported below the strip. Cooperation between the blow pipe and the mold forms the cup 23 as well as `the groove 31 in the longitudinal flange 27 connecting the cups.

The `mold 117 is mounted in a manner similar to the tube 98 of the heating unit 49, i.e., it is carried on ya block 119 slidably carried on four vertical studs 121 secured to the lower reciprocating box-beam 73. The block 119 is provided with countersunk holes 123, and each of the studs is encircled by a coil spring 125. The mold itself is provided with a somewhat U-shaped passageway 127 connected by a conduit 129 to a source of cooled medium -to cool the mold and thus maintain the strip in a formed condition.

The upper face of the mold 117 is provided with a pair of integral mold cavities 131 disposed in side by side relation to each other, and with 'a pair of partial mold cavities 133 also disposed in side by side relation to each other and disposed forwardly of the pair of integral cavities. (In the description of the apparatus, the input end of the apparatus, `i.e., the left end in FIG. 1, will be referred to as the rearward end, and the output end of the apparatus from which the completed packages emerge will be referred to as the forward end.) The partial cavities 133 receive yand support the rearward portion of the previously formed mold while a succeeding cup is being formed, and also serve to insure registry with the mold cavity of the heated portion yof the strip from which the succeeding c-up is formed.

The rim of each of the integral cavities 131 is encircled by a raised rib 135 of relatively shallow height and narrow width and the rearward and side portions of the rim of the partial cavities 133 are bordered :by a similar rib 136. The forward segment of the rib 135 of each integral cavity and the rearward segment of the rib- 136 of each partial cavity are parallel to one another and relatively closely spaced so as to define therebetween a narrow channel 137. In the molding operation, the strip 21 is formed around the ribs 135 to form the raised lip 30 which encircles the mouth of each cup, and that portion of the strip which overlies the channel 137 is formed t0 provide `the groove 31 of the cup flange 27, previously referred to, into which the cover sheet 33 is tucked to provide the desired registry.

The blow pipe 115 is rigidly mounted in depending position from the T-shaped upper reciprocal beam 53 in vertical alignment with the mold 117 and is provided with a pair of transversely spaced, relatively narrow bores or passageways 141 which are connected by a conduit system 143 to a source of air or other gaseous medium. One of the passageways 141 is disposed over each of the integral mold cavities 131 to form, simultaneously, the two parallel rows of cups 23 previously referred to. The temperature of the medium passing through the passageways 141, being lower than that of the heated strip, is effective to cool the strip somewhat so that it will maintain its formed condition.

In order to form the sheet around the raised rib 135 of `the mold, the lower face of the blow pipe 115 is provided with a pair of downwardly projecting continuous anges 142, each of which has a configuration substantially the same as that defined by the rib 135 of the underlying integral mold cavity and which, when the pipe is moved into cooperating engagement with the mold, encircles the raised rib of the mold and offsets the ange portions of the sheet downwardly around the outer wall of the rib. In the channel 137 between the forward and rearward segments of the ribs of the adjacent integral and partial cavities 131 and 133 respectively, the offset portion of the sheet forms the groove 31, previously referred to, into which the cover sheet 33 may be tucked.

When the upper and lower beams 53 and 73 are reciprocated toward one another, therefore, they bring the pipe 115 and mold 117 together, clamping preheated portions of the strip 21 between them so as to offset the ange portions of the cup downwardly and form the groove 31. The clamping and offsetting of the strip in this manner not only provides the groove 31 which facilitates registry of the surface markings of the cover sheet with the cups, but also provides a more positive engagement between the pipe and mold and the strip so as to eliminate any possibility of slipping or shifting of the strip incident to the pressure exerted thereon when cooled air or gas is forced through the passageways 141 of the pipe to cause the strip to conform to the shape of the integral cavities 131 of the mold to form the cup. This positive gripping or clamping action also provides a cup having more uniform wall thickness because of the absence of such slipping or shifting.

Blanking Station After leaving the forming station 39 and before entering the filling station 43, the row of cups is moved past a blanking mechanism 145 which removes a portion of the transversely extending flange 29 to form an elongated opening 147 (FIG. l). In the completed package, a portion of the cover sheet 33 overlies this opening and may be easily grasped independently of the flange when it is desired to remove the cover sheet and open the package.

The blanking mechanism 145 is shown in FIG. l2 and comprises generally a stationary base portion 149 carried on a beam 148. A hole 151 extending generally vertically through the base 149 receives a punch 153 and facilitates the removal of the portion blanked from the strip. A guide plate 155 overhangs the base 149 and includes an opening 157 therein surrounded by a sleeve 159 through which the punch 153, carried on the lower end of a shaft 161 connected to a reciprocal beam 163, moves. Movement of the beam 163 is accomplished through a linkage 164 which connects the beam to the power means of the apparatus. A stripper nger 165 (FIG. 12) is secured to the lower guide plate 155 and extends beneath the opening 157 of the plate to strip the row of cups from the punch after the blanking operation.

Feeding station After leaving the blanking die, the cups pass into the feeding station 43 where they are individually lled with the product such as a jelly, jam or the like. The mechanism of the feeding station may be of any construction well known in the art and, in the illustrated embodiment (FIG. 1), includes a pair of nozzles 166 depending from the lower edge of a container or hopper (not shown) in alignment with each of the parallel rows of cups. Metering means (not shown) are also preferably provided for dispensing a predetermined amount of product through the nozzles and into the underlying cups each time the movement of the cups is halted.

C overng station The mechanism of the covering station 45 disposes the cover sheet 33 in overlying relation to the rows of cups 23, seals the cover sheet to raised lip 30 of the border flange of each of the cups, and also insures that one of the integral surface markings 35 on the cover sheet will be in registry with each of the cups. Referring to FIG. 2 of the drawings, it will be seen that in the illustrated embodiment, each of the surface markings 35, when in proper registry with one of the cups 23, is disposed with its center located approximately at the center of the area defined by the mouth of the cup. However, as previously mentioned, the term registry as used herein refers to the disposition of a surface marking in any predetermined location relative to one of the cups.

Very generally, the desired registry is accomplished by providing the cover sheet 33 with a series of indicator marks 167 spaced a predetermined distance apart, such as a distance approximately equal to the length of one cup, i.e., the dimension of a cup as measured in the direction of strip movement. The indicator marks 167 are so disposed that when one of the surface markings 35 of the cover sheet is in registry with one of the cups, one of the indicator marks 167 is in alignment with a predetermined point of a sensing means 169 of the apparatus. The sensing means 169 (FIGS. 8 through 11) includes a light source which directs a beam of light at the portion of cover sheet which is adjacent the predetermined point, and a photoelectric cell which receives the refiected beam. The indicator mark has a reflective capacity which differs from that of the remainder of the cover sheet so that the amount of light received by the photoelectric cell and, hence, the magnitude of the current emitted thereby will depend upon whether the indicator mark is in alignment with the beam or not. If the alignment of the mark with the beam falls beyond predetermined limits, as if the surface markings lag the cups, a tucking mechanism 175 is actuated to cause a tucking finger 177 driven by a solenoid (not shown) to pull the cover sheet forward slightly relative to the cups by tucking it into the groove 31 of the flange. The tucking is repeated for successive cups until the indicator mark 167 is once again in alignment with the point of the sensing means and the surface markings 35 of the cover sheet 33 are, accordingly, again in registry with the cups 23.

In the illustrated embodiment, the cover sheet 33 is provided with a white reflective surface and the indicator mark 167 is preferably a small stripe of black or other dark color which will reflect a lesser amount of light than will the remainder of the cover sheet. Accordingly, the sensing means 169 is set to actuate the tucking mechaf nism 175 whenever the current emitted by the photoelectric cell exceeds a predetermined maximum value, thus indicating that the indicator mark 167, which is essentially non-reflective, is no longer in alignment, within the desired limits, with the light beam. Of course, the

system could also be designed with the indicator mark being of a more reflective nature than the cover sheet and with the sensing means being set so that it will actuate the tucking mechanism whenever the magnitude of the current emitted by the photoelectric cell falls below a predetermined minimum value.

In the illustrated embodiment, the indicator marks 167 are located approximately midway of the width of the cover sheet 33 and are spaced from one another a distance slightly greater, e.g., 0.05 inch, than the width of one of the cups 23. Accordingly, there will always be a tendency for the surface markings to lag behind the cups and to fall out of registry. This built-in lag insures that any lack of registry can be compensated for by the tucking operation which brings the surface markings back into registry.

Referring now in detail to the covering station (FIGS. 8 through 11), a pair of brackets 181, are secured to opposite sides of the frame of the apparatus and are adapted to support the cover sheet in roll form. The cover sheet 33 is fed from the roll, downwardly past the sensing means 169 over a pair of vertically spaced rollers 187, and horizontally into overlying relation to the row of formed cups 23. The cover sheet and cups pass together between upper and lower components of a heat sealing unit 189 and a cooling unit 191, the former of which also includes the tucking mechansim 175, soon to be described. A pair of weighted idler rolls 193 rests upon the cover sheet as it enters and leaves the sealing units 189 and 191 to insure a close contact between the sheet and the anges of the cups.

The sensing means 169 is mounted Within a box-like housing 195 situated intermediate the vertically spaced rollers 189, the housing 195 being so disposed that its rearwardly directed wall 197 is in face contact with the cover sheet 33 as the sheet rides on the rollers. The rear Wardly directed wall 197 is provided with an aperture or slit 199 (FIG. 10) through which the light beam of the sensing means passes and which, therefore, defines the predetermined point with which the the indicator mark 167 is normally aligned when the surface markings or messages 35 of the cover sheet are in registry with the cups.

Projecting from the inner surface of the rearwardly directed Wall 197 of the housing 195, and located on a line passing through the aperture 199, is a horizontal ange 201 which serves to separate the light source and the photoelectric cell so that the only light reaching the cell will be that which is reflected by the cover sheet. The ange is cut away slightly immediately adjacent the aperture, as at 203 (FIG. 11), to permit passage of the direct beam and the reflected beam from and to the light source and photoelectric cell.

Each of the light source and photoelectric cell is contained in cylindrical casings 205 and 207 respectively, the light source casing 205 being pivotally carried on a bracket 209 mounted on the upper wall 211 of the housing 195 and the photoelectric cell being pivotally carried on a bracket 213 mounted on the lower wall 215 of the housing. Of course, the relative positions of the light `source and cell might be reversed if desired. The light source is connected by a suitable conductor 217 to a source of electrical energy (not shown), and the photoelectric cell is connected by a similar conductor 219 to a relay (not shown).

Referring to the operation of that portion of the sensing means thus far described, it should be noted that after the leading edge of the cover sheet 33 has been initially sealed to the row of lcups 23, the sheet is pulled through the covering station by the moving cups. Since the movement of the cups is intermittent, the movement of the cover sheet is also intermittent and is in xed increments. ri`he sensing means 169 is energized only when the cover sheet is not in motion. If, at such time, an indicator mark 167 is aligned with the aperture 199 of the housing, no appreciable amount of light from the light source will be reflected by the cover sheet 33 to the photoelectric cell, and little or no current will be generated by the cell. As the indicator Imark 167 begins to fall out of alignment with the aperture 199 upon successive movements of the cover sheet, the amount of light reflected by the cover sheet and, hence, received by the photoelectric cell, increases until it reaches a maximum predetermined value, as when no portion of the indicator mark is in alignment with the aperture. At such point, the maximum current is generated by the photoelectric cell and is of suicient magnitude to close the relay, previously referred to but not shown, which actuates the tucking mechanism 175. The tucking is repeated during each cycle until the alignment of the indicator mark 167 with the aperture 199 is restored.

The cover sheet 33 may be secured .to the containers or cups in any number of ways but, in the illustrated embodiment, is preferably provided with a thin film of a thermoplastic adhesive on its lower surface which is placed in pressure contact with raised lip 30 of the border flange 25 of the cups and heated so as to become releasably bonded thereto. Accordingly, the tucking and sealing mechanism, shown most clearly .in FIGS. 8 and 9, comprises the sealing and cooling units 189 and 191 respectively, each of which includes an upper and a lower component vertically reciprocated toward and away from one another. The units 189 and 191 are located along the path of travel of the containers, with each container being engaged once by each unit, thereby ensuring that the cover sheet will be securely fastened to the container. The tucking mechanism is incorporated into the rearwardmost sealing unit 189, as hereinafter described.

More specifically, the lower components of each of the units are supported on a plate 225 extending transversely of the frame of the apparatus beneath the path of travel of the containers. A brace 227 depends from the plate 225 and carries at its lower end a follower 229 traveling in an eccentric groove 231 of a cam wheel 233 rotated by the power means (not shown) of the appara- 9 tus. When the wheel 233 rotates, the plate 225 and, hence, the lower units are reciprocated vertically toward and away from the path of travel of the containers.

Each of the lower components is supported in a manner similar .to that of the lower heating tube 98 and mold 117 of the forming station 39, i.e., each is carried by a block 235 mounted upon four studs 237 secured to a second block 239 fixed to the reciprocally movable plate 225. The upper block 235 upon which the lower components are carried is biased in a direction away from the lower block 239 by coil springs 241 which encircle the studs.

The lower components of the sealing units are substan- .tially identical in that each is provided on its upper face with a pair of side-by-side cavities 243 which receive the filled cups of the adjacent rows. A continuous rib 244 surrounds each of the cavities 243 and accommodates the raised lip 30 of each of the cups. The lower component of the heat sealing unit 189 is provided with a plate 245 adjacent its forward edge which supports the raised lip of the preceding container. The rib 244 and plate 245 define therebetween a channel 246 which receives the downwardly offset portion of the border flange which defines the groove 31. The channel 246 supports the grooved portion of the fiange during the tucking of the cover sheet into the groove.

The upper components of the sealing and cooling units 189 and 191 are carried in vertical alignment with the lower components by an upper beam structure 247 which is also reciprocated by a suitable connection (not shown) to the power means of the apparatus. The upper portion of .the heat sealing unit 189 comprises generally a vertically disposed post 249 while the upper component of the cooling unit comprises a similar post 250. Each of the posts 249 and 250 has a platen 251 at its lower end and a transverse passageway 253 adjacent the platen 251 through which a temperature-controlled medium carried thereto by a conduit (not shown) may be circulated. A heated medium is circulated through the passageway 253 of the unit 189 to heat the platen and thus effect heating of the cover sheet 33, while a coolant is circulated through the unit 191 to cool the platen and thus effect a cooling and sealing of the cover sheet. The lower faces of the platens 251 are flat and engage the u-pper surface of the cover sheet 33 and bond it to the raised lip of the flange of the container. Both of the upper components of the sealing units are substantially identical in structure to one another except for the tucking finger 177, hereinafter described, which is carried by the rearwardmost sealing unit 189.

The tucking operation is accomplished by the finger 177 which is in the form of a sliding plate carried adjacent the rearward upper sealing post 249 of the rearward unit 189 by a guide screw 255 which occupies a slot (not shown) provided in the plate. The upper end of the plate 177 is secured to the foot 256 of a vertically movable actuating arm 257 connected to the movable armature of the solenoid, previously referred to, which is mounted Within a housing 259 carried on the frame of the apparatus. The actuating arm 2-57 is guided in its vertical movement by a guide rod 261 which projects upwardly from a boss 263 extending from the forward face of the rearward post 249 and occupies a bore 263 provided in the actuating arm. A coil spring 26-5 encircles the guide rod 261 and biases the actuating arm 257 into a retracted position (FIG. 9).

When the solenoid is actuated, as when the indicator mark 167 is no longer in alignment with the aperture of the sensing means and the relay is closed, the actuating arm 257 ymoves downwardly, moving the tucking plate or finger 177 into a position wherein it extends downwardly past the lower face of the platen 251 of the upper post 249. When the upper component of the rearward uni-t is reciprocated downwardly therefore, the finger 177 engages the cover sheet prior to engagement thereof by the platen 251, thereby drawing the cover sheet for wardly a .short ydistance relative to the cups as it is tucked into the groove 3:1 of the underlying container. If the distance which the cover sheet moves relative to the cups is not sufiicient to restore the registry, the tucking is repeated.

When the tucking plate or finger 177 is retracted, of cou-rse, as when the indicator mark 167 is aligned with the Iaperture of the sensing means and the relay is open, the cover sheet is sealed to the flange of the underlying container without any tucking taking place.

Severng station After the containers have been provided with a cover sheet in the covering station 45, they are carried to the mechanism of the trimming and severing station 47, shown in FIGS. 13 and 14, which removes excess portions of the border ange from the packages and separates them from one another. The mechanism includes upper and lower reciprocating sections 267 and 269 respectively, the lowermost section 269 of which is carried on a box beam 271 Which is driven through a cam and follower connection 273 to the power means (not shown) of the apparatus. The lower section 269 comprises generally a fixture 275 provided with a suitable cavity 277 to receive the cup portion of the package and a suitable hole 279 into which the trimmed portions of the flange will fall. The fixture also includes a cutting block 2181 which cooperates with a knife blade 283 carried by the upper section 2617 in severing the packages from one another along a longitudinally extending line.

The upper section 269 of the trimming and severing unit is carried on a vertically reciprocating upper beam 285 which extends transversely above the path of movement of the packages and Which comprises a punch 287 and the knife blade 283. The punch 287 (FIG. 14) is suitably shaped to impart the desired configuration to the border ange of the pack-ages and comprise generally a web portion 288 which removes a portion of the longitudinally extending border flange 27 so las to separate the cups in each row from one another along the lgroove 31, and end portions 289, which provide rounded corners for the ange. A stripping plate 290 is suspended from the beam 285 in surrounding relation to the die 287.

The knife blade 283` is mounted forwardly of the die and cooperates with the knife blade 281 to sever the transversely extending border flange 29 and thus separa-te the packages of adjacent rows from one another along a longitudinally extending line.

The completed packages, after having been severed from one another in the blankin-g unit, are carried to the forward end of the apparatus by a suitable conveyor means where they are packed for shipment.

An apparatus has thus been disclosed which is adapted to package items suc-h as food products in individual serving containers, each container being provided with a cover sheet having a series of integral surface markings. The apparatus is adapted -to cause each of the surface markings to register with one of the packages so as to provide a package having a neat and attractive appearance.

While various features of the invention have been shown with reference to one specific embodiment thereof, it should be apparent that various structural modifications may be made therein without departing from the scope of the invention. For example, it would be possible to form several strips rather than a single strip of material simultaneously into the parallel rows of cups. Also, although the method and apparatus has been described with reference to the use of a thermoplastic material, it should be apparent that other suitable material might also be used.

What is claimed is:

1. In a packaging apparatus in which a row of interconnected open-topped containers is moved along a predetermined path, the containers of said row `being interconnected by a flange extending between the upper portions of adjacent containers, a portion of said flange being offset downwardly along a line extending transversely of said row to form a groove therein, said containers having disposed therein the material to be packaged; means for supplying a continuous sheet of covering material to a position overlying said row, said covering material being adapted to be sealed across the open tops vof said containers and being provided with a continuous series of integral surface markings, and means for effecting a registration within predetermined limits of one of said surface markings with each of said containers including means for detecting a longitudinal deviation of said markings from said registration and means for causing a portion of said cover sheet to be tucked into at least one of said grooves of said interconnecting flange so as to cause it to occupy said one groove during the sealing of the covering material to the container immediately succeeding the one groove so as to at least partially compensate for said deviation.

2. A packaging apparatus comprising means for forming a continuous sheet of thermoplastic material into a row of cup-shaped containers having an open-mouth defined by a lip, the adjacent containers of said row being interconnected by a ange extending between the lips thereof, means for offsetting la portion of said flange downwardly along a line extending generally transversely of said row to form a groove therein, means for filling each of said cups with the material to be packaged, means for supplying a continuous sheet of covering material to a position overlying said row, said sheet of covering material being adapted to be sealed across the open tops of said containers and being provided with a continuous series of integral surface markings, said markings being spaced from one another a distance slightly greater than the length of one of said containers, and means for effecting a registration longitudinally of said row of one of said surface markings with each of said containers within predetermined limits including means for detecting a longitudinal deviation of said markings from said registration and means for tucking a portion of said cover sheet into at least one of said grooves so as to at least partially compensate for said deviation.

3. In a packaging apparatus in which a row of interconnected open-topped containers is moved along a predetermined path, t-he containers of said row being interconnected by a fiange extending between the upper portions of adjacent containers, a portion of said fiange being offset downwardly along a line extending transversely of said row to form a groove, said containers having disposed therein the material to be packaged; means for intermittently supplying a continuous sheet of covering material to a position overlying said row, said covering material being adapted to be sealed to the upper surface of the flanges of said containers and being provided with a continuous series of integral surface markings and with an indicator mark at predetermined spaced intervals, said indicator marks being positioned so that when said integral surface markings are in proper registration with said containers, one of said markings will be in alignment with a predetermined fixed point remote from said row of containers, photoelectric means at said fixed point adapted to detect misalignment of said indicator mark With said fixed point and hence a lack of registry of said integral surface markings With said containers, and means responsive to said photoelectric means for causing a portion of said cover sheet to be tucked into at least one of said grooves so `as to cause it to occupy said one groove during the sealing of the covering material to the container immediately succeeding the one groove when said misalignment i s detected `S9 as to at least partially restore said indicator marks into alignment with said fixed point and thereby restore registration of said integral surface markings with said containers.

4. An apparatus as set forth in claim 3 in which Said surface markings and said indicator marks are spaced apart on said cover sheet a distance slightly greater than the distance across one cup measured longitudinally of the row so as to cause said surface markings to tend to deviate from said registry in a given longitudinal direction, and wherein said tucking is adapted to compensate for deviation in said given direction.

5. The method of forming =a package comprising an open-topped container and a cover sheet extending across the top of said container and secured thereto, said cover sheet including a surface marking disposed in predetermined registry with the upper surface of said container, which method includes the steps of forming a sheet of material into a row of longitudinally spaced cups interconnected by a border fiange extending betweenthe cups, offsetting said border flange downwardly between said cups so as to form a groove extending transverselyof the row, disposing a continuous cover sheet having thereon a series of integral surface markings in overlying relation to said row with one of said markings being approximately in registry with each of said containers, and tucking a portion of said cover sheet into the grooves of said fianges to adjust said cover sheet relative to said containers so as to achieve the predetermined registry desired. y

6. The method of forming a package comprising an open-topped container and a cover sheet extending across the top of said container and secured thereto, said cover sheet including a surface marking disposed in predetermined registry with the upper surface of said container, which method includes the steps of forming a sheet of material into a row of `longitudinally spaced cups interconnected by a border flange extending between the cups, offsetting said -border flange downwardly by clamping said fiange between a mold having a raised rib on its upper surface and a blow pipe having a depending flange on its lower surface adapted to encircle said rib, said clamping being effective to form a groove extending between said cups transversely of the row, disposing a continuous cover sheet having thereon a series of integral surface markings in overlying relation to said row with one of said markings being approximately in registry with each of said containers, and tucking a portion of said cover sheet into the grooves of said flanges to-adjust said cover sheet relative to said containers so as to achieve the predetermined registry desired.

7. In a packaging apparatus in which a row of interconnected open-topped rimmed containers is moved along a predetermined path, said containers having disposed therein the material to be packaged, means for closing each of said containers with a sheet of covering material having an integral surface marking in registry with the space defined by the rim of the container, said closing means comprising means for supplying a continuous sheet of covering material for said containers to a position overlying said row, said covering material being adapted to be sealed across the open tops of said containers and being provided with a continuous series of spaced-apart integral surface markings, and means for sealing the covering material to the containers with one of the surface markings in registration, within predetermined limits, with each container, said latter-mentioned means comprising means for establishing a pocket of covering material between adjacent preceding and succeeding containers of the row during the sealing of the covering material to the succeeding container when the formation of such a pocket tends to effect such registration.

S. In a packaging apparatus in which a row of interconnected open-topped rimmed containers is moved along a predetermined path, said containers having disposed therein the material to be packaged, means for closing each of said containers with a sheet of covering material having an integral surface marking in registry with the space defined by the rim of the container, said closing means comprising means for supplying a continuous sheet of covering material for said containers to to position overlying said row, said covering material being adapted to be sealed across the open tops of said containers land being provided with a continuous series of spaced-apart integral surface markings, and means for sealing the covering material to ythe containers with one of the surface markings in registration, within predetermined limits, with each container, said latter-mentioned means comprising means for detecting a deviation of the markings from said registration, means for establishing a pocket of covering material between adjacent preceding yand succeeding containers of the row during the sealing of the covering mate-rial to the succeeding container, and means responsive to said detecting means for actuating said pocket-establishing means when the establishment of a pocket tends to eiect such registration.

References Cited by the Examiner UNITED STATES PATENTS TRAVIS S. MCGEHEE, Primary Examiner.

Disclaimer 3,238,691.ROZand E. Miller, Orangoville, Geowge Hoz/ard Kraft, lVlmette, Carmen G. Tumfno, Elk Grove Village, und Clyde D. Wayne, lVilmette, Ill PACKAGING MATERIAL REGISTER CONTROL. Patent dated Mar. 8, 1966. Disclaimer filed July 24, 1970, by the assignee, Kmftco Uorpomtmi.

Hexeby enters this disclaimer lo claims 1 through 8 of said patent.

[Ocz'al Gazette Novem/)ef J0, 1970.] 

5. THE METHOD FOR FORMING A PACKAGE COMPRISING AN OPEN-TOPPED CONTAINER AND A COVER SHEET EXTENDING ACROSS THE TOP OF SAID CONTAINER AND SECURED THERETO, SAID COVER SHEET INCLUDING A SURFACE MARKING DISPOSED IN PREDETERMINED REGISTRY WITH THE UPPER SURFACE OF SAID CONTAINER, WHICH METHOD INCLUDES THE STEPS OF FORMING A SHEET OF MATERIAL INTO A ROW OF LONGITUDINALLY SPACED CUPS INTERCONNECTED BY A BORDER FLANGE EXTENDING BETWEEN THE CUPS, OFFSETTING SAID BORDER FLANGE DOWNWARDLY BETWEEN SAID CUPS SO AS TO FORM A GROOVE EXTENDING TRANSVERSELY OF THE ROW, DISPOSING A CONTINUOUS COVER SHEET HAVING THEREON A SERIES OF INTEGRAL SURFACE MARKINGS IN OVERLYING RELATION TO SAID ROW WITH ONE OF SAID MARKINGS IN OVERLYAPPROXIMATELY IN REGISTRY WITH EACH OF SAID CONTAINERS, AND TUCKING A PORTION OF SAID COVER SHEET INTO THE GROOVES OF SAID FLANGES TO ADJUST SAID COVER SHEET RELATIVE TO SAID CONTAINERS SO AS TO ACHIEVE THE PREDETERMINED REGISTRY DESIRED. 